Fireproof panel and a method for its manufacture

Abstract: A fireproof panel is described which comprises at least one sheet including a layer of glass fibres impregnated with at least one fireproof resin free from solvent. A method for the manufacture of this panel is also described and includes the successive steps of distributing a fireproof resin in the form of a powder free from solvents on a layer of glass fibres, subjecting the latter to a first compression and heating step to soften the resin and to a second compression and heating step to cross-link the resin and form the said sheet.

Description: In its more general aspect, the present invention relates to panels or like structures which are fireproof and are usable as constituent elements of partitions or furniture. Moreover the present invention relates to a method for the production of fireproof panels suitable for the production of partitions and furniture for ships or aircraft, as well as panels obtained by this method. In the field of furnishing equipment for aircraft and ships, particularly for merchant ships, there is a great need for structural elements such as bulkheads and elements of furniture made from fireproof materials which do not transmit flames and form a barrier to the propagation of heat, without giving off fumes or toxic vapours. The materials usable for this purpose must answer very precise and often very strict requirements set out in the laws in force in various countries. In Italy, for example, these requirements are established by the regulations of the Italian Register of Shipping (RINA), prepared in accordance with international shipping-safety standards established by the SOLAS Convention 74(83). In addition to satisfying this primary requirement, research has for some time been directed at finding materials which enable the manufacture of lightweight structural elements, including self-supporting elements, with little bulk and which are readily workable by a machine so as to be very versatile with regard to their use or applications. It is known that until now this research has given results which are not fully acceptable since, in general, the materials proposed do not answer the primary requirements listed above. The problem at the basis of the present invention is that of providing a fireproof panel suitable for the manufacture of partitions and furnishings for ships and aircraft which has all the properties specified above. This problem has been resolved by a fireproof panel as defined in claim 1. A phenol-formaldehyde, particularly a novolac, resin is used as the fireproof resin. The use of the novolac resin LERIPHEN SM 1112 is particularly advantageous. In a preferred embodiment of the invention, the fireproof panel includes at least one element which has two such sheets between which is interposed an aluminium honeycomb structure. The present invention also relates to a method for the production of fireproof panels suitable for the production of partitions and furnishings, including at least one sheet of glass fibres, characterised in that it includes the successive steps of: distributing a fireproof resin uniformly, in the form of a powder free from solvents, on a layer of glass fibres in quantities of at least 5g per 100g of the glass fibres, compressing the layer and heating it to a temperature at which the resin softens for sufficient time to cause the softening thereof, compressing the layer further at the crosslinking temperature of the resin to obtain the said sheet. To advantage the fire-proof resin is a phenolformaldehyde resin. The quantity of fireproof resin distributed on the layer of glass fibres is preferably between 5 and 6g per 100g of glass fibres. Preferably the step of compression and softening of the resin is carried out at a temperature of 80-100°C, at a pressure of 1.5-2 atmospheres and for 5-7 minutes and the step of compression and cross-linking of the resin is carried out at a temperature of 180-220°C, at a pressure of 1.5-2 atmospheres and for 5-7 minutes. In a preferred embodiment of the present invention, the compression steps are carried out by placing the said layer between the heated surfaces of respective presses. During the compression and softening of the resin, the surfaces of the respective press are preferably heated to 90°C. During the compression and cross-linking of the resin, the surfaces of the respective press are preferably heated to 200°C. A phenol-formaldehyde resin which is particularly useful for the method described above is the novolac resin LERIPHEN SM 1112 made by the firm Industrie Chimiche Leri. The fire-resisting properties of phenol-formaldehyde resins have been known for some time but fireproof panels and sheets made with the use of these resins, and able to satisfy the requirements set out above, are not known. The reason for this must be attributed to the fact that these panels or sheets, if prepared by the usual methods of impregnation based on contact with solutions of the resin in organic solvents, have good fireproof and heat-shielding properties but when exposed to high temperatures, inevitably give off vapours and toxic gases. With the method of the present invention, instead, it is found, surprisingly, that perfect impregnation of the layers of glass fibres with the selected fireproof resin is obtained, particularly with a phenolformaldehyde resin, without the use of any solvent, simply by softening the resin applied in the dry, powdered state, without organic solvents, by mild compression (1.5 to 2 atmospheres) for example between the plates of a press heated to 80-100°C for 5-7 minutes. In these conditions the resin acquires a treacle-like consistency and impregnates the fibres uniformly. A second compression step, at the same pressure but at a higher temperature (180 to 220°C), between the heated plates of a press for 5 to 7 minutes, causes crosslinking of the resin, enabling sheets to be obtained which not only have very good fire-resisting and heat-shielding properties but are also easy to handle in that they are self-supporting. If an aluminium honeycomb structure is interposed between two sheets prepared by the method of the invention with the use of fixing means such as a fire-proof glue which does not give off toxic gas or vapour at high temperatures, such as, for example, the adhesive polyurethane XC 189 E made by the firm EXCEL or the adhesive DUNAPOL SP 1500 made by the firm DUNA-CORRADINI, panels are obtained which may be used in the manufacture of partitions, bulkheads and furnishing elements such as furniture, particularly for ships. Further advantages and characteristics of the invention will become more apparent from the embodiment of the method described above and from the results of tests carried out on fireproof panels and sheets made by this method, given below by way of non-limitative example. EXAMPLE A phenol-formaldehyde resin of the novolac type sold by INDUSTRIE CHIMICHE LERI under the name LERIPHEN SM 1112 was distributed uniformly over a 1.2mm-thick layer of glass fibres in quantities of 5g per 100g of glass fibre. The layer was then compressed to a pressure of 2 atmospheres between the plates of a press heated to a temperature of 90°C so as to cause the softening of the resin and the complete impregnation of the layer with the resin itself. The compression and the heating lasted for 7 minutes after which the layer was transferred to another press. Here the layer was compressed to a pressure of 2 atmospheres between two plates heated to a temperature of 200°C for 7 minutes, thus causing the cross-linking of the resin and the formation of a sheet. After cooling to ambient temperature, the sheet had a density of 1.35 kg/dm 3 and was ready for use in the production of fire-proof panels. The fire-resistant properties of the sheet prepared in this manner were checked by a test carried out in accordance with the RINA regulations, also in accordance with international shipping-safety standards governed by the SOLAS Convention 74(83). More particularly, several sheets produced by the method of the embodiment above, were superposed until a 50mm-thick slab was obtained, the individual sheets being held together by a wire cage. Temperature-measuring thermocouples were applied to the centre of the thickness of the slab and to its surface. The slab thus arranged was introduced into an oven which had previously been brought to a running temperature of 750 +/- 10°C and the temperature at the centre and the surface of the slab were then detected, as was the temperature in the oven, for a period of 20 minutes. Any appearance of flames was also checked. The test was carried out on 5 samples, giving the results shown in the following table: Sample No. Tof (°C) Tmax,f (°C) Tmax,s (°C) Tmax,c (°C) 1 740 780 780 810 2 740 790 765 805 3 740 780 785 795 4 740 780 780 815 5 740 780 765 800 Total 3700 3910 3875 4025 Average 740 782 775 805 in which Tof represents the initial temperature of the oven, Tmax,f is the maximum temperature reached by the oven, Tmax,s is the maximum temperature reached at the surface of the slab and Tmax,c is the maximum temperature at the centre of the slab. According to RINA standards, a fire-proof material must result in a maximum rise in temperature in the oven of no more than 50°C degrees above the initial temperature of the oven. From the table one may deduce a maximum rise of 42°C degrees (Tmax,f - Tof). Again, according to the said regulations, the maximum rise in temperature at the surface of the sample must not exceed the initial temperature of the oven by more than 50°C degrees; in the present case a rise of 35°C degrees is found. The RINA regulations also provide that, should flames appear, these must not last for more than 10 seconds. The slab subjected to the test did not give rise to any flames. Finally the loss in weight of the slab at the end of the test was 2.04% of the original weight, well below the 50% limit allowed by the regulations mentioned above. The slab produced by the method of the invention may be used for manufacturing fireproof panels. One embodiment of such panels will now be described with reference to the appended drawing, in which: Figure 1 is a schematic section of part of a fireproof panel manufactured with the use of the sheets produced by the method of the invention. In the drawing, a fireproof panel according to the invention is generally indicated 1. It comprises two flat elements indicated 2 and 2' respectively, placed facing each other, parallel and separated by an interspace 3. When the elements 2, 2' of the panel 1 are put to use in partitions and furnishings, they will be supported by frames not shown. The elements 2, 2' have the same structure but are placed in mutually mirror-imaged positions. The structure of only one of the two flat elements 2, 2' will therefore be described below. The element 2 includes two sheets, indicated 4 and 5 respectively, placed facing and parallel to each other. The sheet 5 together with its corresponding sheet of the flat element 2' define the sides of the panel 1. Between the sheets 4 and 5 is a honeycomb structure 6 of metal, preferably aluminium, held in contact with both of the sheets 4, 5, being glued to them, and acting as a support for them. In addition, between the sheet 4 and a further sheet 7, is a mat 8 of aluminosilicaceous fibres. The sheet 7, together with its corresponding sheet in the flat element 2', define the interspace 3. The sheets, 4, 5 and 7 are produced by the method of the present invention. The panel described above was subjected to a test for resistance to combustion for conformity with the international safety regulations. In particular the panel subjected to testing had the following structural data: thickness of the sheets 1 mm thickness of the honeycomb structure 10 mm thickness of the mat 17 mm thickness of the interspace 10 mm The honeycomb structure, the sheets and the mat were glued together with the fireproof polyurethane adhesive XC 189 E made by the company EXCEL (France). The said panel was applied vertically to the opening of an oven so as to close this opening exactly and so that only one face of the panel was exposed to the flames. Five thermocouples were arranged over the surface of the panel facing out of the oven to detect its temperature. The same number of thermocouples were arranged in the oven to measure its temperature. The temperature within the oven was raised gradually over 30 minutes along a predetermined gradient and, at the same time, the values of the temperature at the surface of the panel facing outwardly of the oven were determined. From the average of the readings of the five thermocouples, the following results were obtained: 5' 10' 15' 20' 25' 30' Temperature of the oven (°C) 508 687 743 798 819 834 Temperature of the outer face of the panel (°C) 28 29 35 46 65 93 As may readily be deduced from the data given above, the fireproof panel manufactured with the use of the sheets produced by the method of the invention, as well as not allowing the passage of flames, had excellent heat-shielding properties. In addition, at the end of the test, the panel was whole.

Claims: A fireproof panel (1) including at least one sheet (4,5) that does not give rise to any flames when heated at 750°+/-10°C for a period of 20 minutes, wherein said at least one sheet (4,5) consists of a layer of glass fibres impregnated with at least one phenol-formaldehyde fireproof resin free from solvents, characterized in that said at least one phenol-formaldehyde resin and said glass fibres are in a weight ratio of 5:100 to 6:100. A fireproof panel (1) according to Claim 1, characterised in that said at least phenol-formaldehyde fireproof resin is a novolac resin. A fireproof panel (1) according to Claim 1, characterised in that it includes at least two sheets (4, 5) consisting of a layer of glass fibres impregnated with at least one phenol-formaldehyde fireproof resin free from solvents. A panel (1) according to Claim 3, characterised in that it includes at least one element (2, 2') comprising two of the said sheets (4, 5) with an aluminium honeycomb structure (6) interposed between them. A panel (1) according to Claim 4, characterised in that said at least one element (2, 2') includes a further sheet (7), comprising a layer of glass fibres impregnated with at least one fireproof resin free from solvent and has at least one mat (8) of aluminosilicaceous fibres between one of said two sheets (4, 5) and said further sheet (7). A method for the production of a fireproof panel (1) according to claim 1, said method being characterised in that it includes the successive steps of: distributing a phenol-formaldehyde fireproof resin uniformly, in the form of a powder free from solvents, on a layer of glass fibres, in quantities of at least 5g per 100g of the glass fibres, compressing the layer and heating it to a temperature at which the resin softens for sufficient time to cause the softening thereof, compressing the layer further at the cross-linking temperature of the resin to obtain the said sheet (4, 5). A method according to Claim 6, characterised in that said phenol-formaldehyde resin is distributed on said layer of glass fibres in quantities of 5 to 6 g per 100 g of the glass fibres. A method according to any one of Claims 6 and 7, characterised in that the step of compression and softening of the resin is carried out at a temperature of 80-100°C at a pressure of 1.5-2 atmospheres and for 5-7 minutes. A method according to Claim 8, characterised in that the step of compression and cross-linking of the resin is carried out at a temperature of 180-220°C, at a pressure of 1.5-2 atmospheres and for 5-7 minutes. A method according to Claim 9, characterised in that the compression - softening and cross-linking steps are carried out by placing the layer between the heated surfaces of respective presses. A method according to Claim 10, characterised in that, in the step of compression and softening of the resin, the surfaces of the press are heated to 90°C. A method according to Claim 11, characterised in that, in the step of compression and cross-linking of the resin, the surfaces of the press are heated to 200°C.

Inventors: LUSARDI ADRIANO, LUSARDI, ADRIANO
Applicants: B & B ITALIA SPA, B & B ITALIA S.P.A.
Application year: 1994
Main classification: C08J5
IPC codes: C08J5, E04B1, B32B17, B32B15, E04C2, B32B3, B32B27